Ramp door patio deck system

ABSTRACT

A recreational vehicle (RV) includes a ramp door configurable as a ramp or as a patio deck. A stair is attachable to a side of the door. A railing extends about the perimeter of the door when in the deck configuration. First and second support cables may be connected between the door and the RV to support the door when in the deck configuration.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/649,407, filed Jul. 13, 2017, pending, which claims the benefit ofU.S. Provisional Patent Application No. 62/364,666 filed Jul. 20, 2016,the entire contents of each of which are hereby incorporated byreference in this application.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

(Not Applicable)

BACKGROUND AND SUMMARY

A recreational vehicle or trailer (RV) may be provided with a door(sometimes referred to as a ramp door) that is pivotally connected tothe vehicle proximate a floor thereof and pivotable about an axisparallel to the floor and to a wall (typically a rear wall) of thevehicle in which the door may be installed. Such a door typically has afirst (or connected) end, a second (or free) end, a first side, and asecond side. In embodiments wherein the door is in a rear wall of thevehicle, the first side may be a driver's side and the second side maybe a passenger side. In an embodiment, the ramp door may effectively bethe rear wall of the vehicle.

Such a door may be used in a ramp configuration wherein the door extendsbetween the interior of the vehicle and the ground. In the rampconfiguration, the door may serve as a loading ramp facilitating loadingand unloading of cargo to and from the vehicle. In the rampconfiguration, the connected end of the door typically would besupported by the vehicle and the free end of the door typically would besupported by the ground.

Alternatively, such a door may be used in a deck configuration whereinthe door is parallel to a floor of the vehicle. In this configuration,with the floor of the vehicle and, therefore, the ramp door, leveled,the ramp door can be used as a patio deck. In the deck configuration,the connected end of the door typically would be supported by thevehicle. The free end of the door typically would be supported by afirst support cable extending between an upper portion of the vehicle(or door frame attached to the vehicle) proximate the first side of thevehicle and a first cable mount located proximate the free end and thefirst side of the door, and by a second support cable extending betweenan upper portion of the vehicle (or door frame attached to the vehicle)proximate the second side of the vehicle and a second cable mountlocated proximate the free end and the second side of the door. Thefirst and second cable mounts typically would be located at about thesame distance from the free end of the door, which distance typicallywould be a short distance so that only a small portion of the door wouldbe cantilevered about a line connecting the first and second cablemounts.

With the door in the deck configuration, stairs may be connected to orotherwise provided adjacent the door to provide access between the door(sometimes referred to herein as the “deck” when in the deckconfiguration) and the ground. Such stairs typically extend from thefree end of the deck and away from the vehicle. It would be desirable toextend the stairs from the side of the deck to better integrate the deckwith the area about the entry door of the RV, which typically is locatedon the passenger side of the RV. The foregoing door support cables,however, preclude extending the stairs from the side of the deck becausethe cables would interfere with users accessing the stairs from the deckand vice versa.

A railing may be provided to protect against users falling off of thepatio deck. The railing typically is supported by posts attached to aperipheral edge or surface of the door. The railing typically includes afirst side section extending from the vehicle along the first side ofthe door, a first return section extending from the first side of thedoor along the free end of the door to a first side of the stair, asecond side section extending from the vehicle along the second side ofthe door, and a second return section extending from the second side ofthe door along the free end of the door to a second side of the stair.The first side section and the first return section may beinterconnected so that each such section provides lateral support forthe other. The second side section and the second return section may besimilarly interconnected.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects and advantages will be described in detail withreference to the accompanying drawings, in which:

FIG. 1 is a perspective view of an RV having a ramp door deployed in apatio deck configuration and supported by first and second supportcables, a stair removably attached to a second side of the door, and arailing extending about the perimeter of the door, with a gate in anopen position, thereby allowing access between the stair and the deck;

FIG. 2 is a perspective view similar to that of FIG. 1, with the supportcables omitted for clarity, and with the gate in a closed position,thereby blocking access between the stair and the deck;

FIG. 3 is a perspective view similar to that of FIG. 2, with the gate inan open position, thereby allowing access between the stair and thedeck;

FIG. 4 is a perspective view similar to that of FIG. 1, with the stairomitted for clarity and the gate in a closed position;

FIG. 5 is a side elevation view generally corresponding to theperspective view of FIG. 2;

FIG. 6 is a side elevation view generally corresponding to theperspective view of FIG. 3;

FIG. 7 is a side elevation view generally corresponding to theperspective view of FIG. 4, with the support cables omitted for clarity;

FIG. 8 is a front elevation view generally corresponding to theperspective view of FIG. 2;

FIG. 9 is a front elevation view generally corresponding to theperspective view of FIG. 4, with the support cables removed for clarity;

FIG. 10 is a perspective view of the RV and a door frame (or hoop)installed in a rear wall of the RV with the door omitted for clarity;

FIG. 11 is a perspective view of the RV, the door frame, the doorpivotally attached to the RV and in an open position, and first andsecond support cables connected between the door and the RV or the doorframe;

FIG. 12 is a perspective view of the RV, the door frame, and the doorpivotally attached to the RV and in a closed position;

FIG. 13 is a perspective view of a post mount attached to the door andengaging a post of the railing;

FIG. 14 is a perspective view of the drop leg attached to the stair andthe stair attached to the door;

FIG. 15 is a perspective view similar to FIG. 14, with the stairassembly omitted for clarity;

FIG. 16 is a perspective view of the door, a stair mount attached to thedoor, the stair attached to the stair mount, the railing attached to thedoor, and a support panel pivotally attached to a post of the railingand selectively latched to the stair mount;

FIG. 17 is a cross-sectional view of an H-channel as might be used toform a peripheral frame of the door;

FIG. 18 is a cross-sectional view of the H-channel of FIG. 17 furthercomprising a foam element within a channel section thereof;

FIG. 19 is a cross-sectional view of the H-channel of FIG. 17 furthercomprising a tube within a channel section thereof; and

FIG. 20 is a cross-sectional view of an H-channel similar to theH-channel of FIG. 17 but having a thickened web.

DETAILED DESCRIPTION

The present disclosure illustrates and describes an RV 10 having a rampdoor 12 that can be deployed in a deck configuration, a stair 14removably attachable to a side of the door, and a railing 16 removablyattachable to the door and extending about the periphery of the doorwhen the door is in a deck configuration.

The door 12 has a first (or connected or pivot) end 18, a second (orfree) end 20, a first side 22, and a second side 24. The door 12 may bepivotally connected to the RV 10 in a conventional manner, for example,by a hinge 13 connected to the door and to a door frame (or hoop) 26installed in a wall W (or between walls W) of the RV or directly towalls W, a floor F, or another structural component of the RV. In anembodiment, a first support cable 28 may be connected between the RV 10or the hoop 26 and a first cable mount 30 in any suitable manner, withthe first cable mount located on the door 12 proximate the first side 22of the door and a short, first distance from the free end 20 of thedoor. A second support cable 32 may be connected between the RV 10 orhoop 26 and a second cable mount 34 in an suitable manner, with thesecond cable mount located on the door 12 proximate the second side 24of the door and a second distance from the free end 20 of the door, thesecond distance being substantially greater than the first distance.Typically, the first cable mount 30 is much nearer to the free end 20 ofthe door than to the connected end 18 of the door. Typically, the secondcable mount 34 is nearer to the free end 20 of the door than to theconnected end 18 of the door. In an embodiment, the second cable mount34 could be nearer to the connected end 18 of the door 12 than to thefree end 20 of the door.

With the door 12 in the deck configuration, a portion of the doorbetween the free end 20 of the door and a line connecting the first andsecond cable mounts 30, 34 is thus cantilevered about the lineconnecting the first and second cable mounts. At least the cantileveredportion of the door 12 may be structurally reinforced to withstand loadsapplied to the cantilevered portion. For example, as shown in FIGS.18-20, a structural member 36 of a peripheral frame of the door 12 maybe reinforced with foam or tubing, or the cross-section of one or moreportions of the structural member may be increased to provide additionalstrength. More specifically, FIGS. 18-20 show embodiments of anelongated structural member 36 of the door frame, the member 36 definingan elongated channel C therethrough. FIG. 18 shows a foam element 38disposed within the channel C and adhered to walls of the member 36defining the channel. FIG. 19 shows an ovalized tube 40 disposed withinthe channel C and abutting walls of the member 36 defining the channelFIG. 20 shows a structural member 36′ including at least one wall 37′having a thickness substantially greater than the thickness of ananalogous wall 37 of the member 36 shown in FIGS. 18 and 19.

The stair 14 is removably attachable to the second side 24 of the door12 between the free end 20 of the door and the second cable mount 34.The stair 14 may be attached to the door 10 using any suitable means.For example, one or more stair mounts 42 configured to removably receivea corresponding portion of the stair 14 may be connected to the door 12,for example, proximate a peripheral portion of an inner surface of thedoor (that is, the upper surface of the door when the door is the deckconfiguration. The stair 14 may be removably engaged with the stairmount 42 as desired. In an embodiment, the stair/door connection may besubstantially rigid so that a load applied to the door 12 may besubstantially transferred to the stair 14. In turn, the load may besubstantially transferred to the ground underneath the stair 14. Thestair 14 may be collapsible or have a fixed configuration. The stair 14may include a hand rail 44, which may be removable from the stair.

In an embodiment, a leg 46 may extend from an upper portion of the stair14, proximate the stair mount 42 or the door 12. Alternatively, the leg46 may be connected to the stair mount 42 instead of the stair 14. In anembodiment, the leg 46 may extend from the side of the stair 14 or stairmount 42 closer to the free end 20 of the door 14. So connected, the leg46 may provide support for the free end 20 of the door 12 through thestair 14 or the stair mount 42. The leg 46 may be telescopic orotherwise length-adjustable to accommodate uneven terrain upon which theRV may be parked. A foot 47 may be pivotally (as shown) or fixedlyconnected to the lower end of the leg 46. The leg 46 may be removablefrom the stair 14 or the stair mount 42, or collapsible against thestair to facilitate storage of the stair and the leg.

The railing 16 may include a first side section 50 extending from thefirst side 22 of the RV 10 or hoop 26 to the free end 20 of the door 12,an end section 52 extending from the first side 22 of the door to thesecond side 24 of the door, and a second side section 54 extending fromthe second side of the RV or hoop to the side of the stair 14 distantfrom the free end of the door. The first side section 50 and the firstend of the end section 52 (the end of the end section proximate thefirst side 22 of the door 12) may be interconnected to provide lateralsupport for each other. The first side section 50 may receive additionaloutward lateral support from the first support cable 28. Morespecifically, the first side section 50 may be located inboard of thefirst support cable 28 so that the first support cable may mitigateoutward lateral displacement of the first side section in response to anoutward lateral load applied thereto. In an embodiment, the first sidesection 50 could be removably attached to the first support cable 28. Insuch an embodiment, the first support cable 28 could also mitigateinward lateral displacement of the first side section 50 in response toan inward lateral load applied thereto.

The second end of the end section 52 (the end proximate the second side24 of the door 12) may be removably interconnected with the stair 14 orthe stair mount 42 to provide further lateral support for the endsection. For example, as best shown in FIG. 16, the second end of theend section 52 may include an upright 56 and a latch plate 58 pivotallyattached to the upright, for example, by hinges 59. With the railing 16and the stair 14 installed to the door 12, the latch plate 58 may bepivoted into releasably latched engagement with the stair or the stairmount 42, thereby providing lateral support for that end of the stair.Alternatively, the latch plate 58 may be pivoted into releasably latchedengagement with a further mount (not shown) attached to the door 10.Such a further mount could be similar to the stair mount 42 or the postmounts 64 discussed further below. In an embodiment, the second end ofthe end section 52 could be interconnected with a hand rail 44 of thestair 14, thereby providing lateral support for both the second end ofthe end section and the stair.

The second side section 54 could receive lateral support from the secondsupport cable 32 in a manner similar to that in which the first sidesection 50 receives lateral support from the first support cable 28. Inan embodiment, the second side section 54 could be interconnected with ahand rail 44 of the stair 14 to further provide lateral support for thesecond side section. The second side section 54 may include a gate 60operable to selectively preclude access to the stair 14 from the deck oraccess to the deck from the stair. In an embodiment, the gate 60 may beslidingly engaged with the second side section 54 of the rail 16. Inanother embodiment, the gate 60 may be pivotally engaged with theupright 56 or otherwise with the end section 52. In either embodiment,the gate 60 could be interconnected with the end section 52 when thegate is closed to further provide lateral support for the second sidesection 54.

The railing sections 50, 52, 54 may be supported by posts 62. Any or allof the posts 62 may be length-adjustable. For example, each post mayinclude a first portion 66 and a second portion 68 threadingly connectedto the first portion so that rotation of the first portion with respectto the second portion in a first direction increases the length of thepost, and rotation of the first portion with respect to the secondportion in a second direction decreases the length of the post. Thesecond portion 68 of the post may include a shaft 70 and a head 72 atthe free end of the shaft portion.

Any or all of the posts 62 may be releasably engageable with post mounts64 that may be attached to the door 12. An illustrative post mount 64 isshown in FIG. 13. The post mount 64 includes a latch 74, for example, arotary latch, configured to latch about the shaft 72 of the lowerportion 68 of the post 62 in a manner that captures the head 72 betweenthe latch and the door 12. The post mount 64 may also include a housingor cover 76 connected to the door 12 and overlying the latch 74.

The post mount 64 may be configured to allow the lower portion 68 of thepost 62 to “float” axially between the surface of the door 12 and latch74 when the post is engaged by the latch 74. Such “float” may allow forthe door 12 to deflect a limited amount in an area about the post mount64 without the latch 74 axially engaging and axially moving the post 62.Such door deflection may occur during normal use of the door 12 as apatio deck, for example, in response to persons walking on the door whenthe door is in a deck configuration.

In an embodiment, the first and second support cables 28, 32 and thefirst and second cable mounts 30, 34 could be omitted, and the ramp door12 could be supported in the patio deck configuration by legs located atthe opposite sides of the door near the free end 20 of the door. Suchlegs could include or be similar to the leg 46, and they could beconnected to the door 12 in a similar manner.

The foregoing embodiments are illustrative and may be modified withoutdeviating from the scope of the appended claims. Features disclosed inconnection with a given embodiment may be incorporated into any otherembodiment to the greatest extent possible.

The invention claimed is:
 1. A system comprising: a door frameattachable to a vehicle, the door frame having a first jamb, a secondjamb opposite the first jamb, and a header extending between the firstjamb and the second jamb; a door having a first side, a second side, apivot end, and a free end, the pivot end of the door configured forpivoting about a pivot axis parallel to the header between a firstposition wherein the door is substantially disposed within and/orsubstantially in abutment with the door frame and a second positionwherein the door is substantially perpendicular to the first position,the door comprising a first cable mount proximate the first side thereofand proximate the free end thereof, and the door further comprising asecond cable mount proximate the second side thereof and intermediatethe free end thereof and the pivot end thereof, the pivot end of thedoor being further from the first cable mount than from the second cablemount; a first cable having a first end connected to the first jamb anda second end connected to the first cable mount; a second cablesubstantially shorter than the first cable, the second cable having afirst end connected to the second jamb and a second end connected to thesecond cable mount; and a rail having a first rail section, a secondrail section, and a third rail section, the first rail section removablyconnectable to the first side of the door frame and removablyconnectable to the first side of the door between the pivot end of thedoor and the free end of the door, the second rail section removablyconnected to the second side of the door frame and removably connectableto the second side of the door, and the third rail section removablyconnectable to the free end of the door between the first side of thedoor and the second side of the door.
 2. The system of claim 1 the thirdrail section comprising an upright and a latch plate pivotally connectedto the upright.
 3. The system of claim 1 further comprising a supportleg removably connectable to the door proximate the free end of thedoor.
 4. A ramp door patio deck system cooperable with a vehicle rampdoor, wherein the vehicle ramp door is pivotable in a door frame betweena closed position and a deck position, the ramp door patio deck systemcomprising: a first cable mount securable to one side of the vehicleramp door; a second cable mount securable to an opposite side of thevehicle ramp door; a first cable having a first end connectable to thedoor frame and a second end connected to the first cable mount; and asecond cable having a first end connectable to the door frame and asecond end connected to the second cable mount, wherein a length of thefirst cable positionable between the door frame and the vehicle rampdoor is longer than a length of the second cable positionable betweenthe door frame and the vehicle ramp door.
 5. The ramp door patio decksystem of claim 4 further comprising a stair removably connectable tothe opposite side of the door, the stair being positionable beyond areach of the second cable.
 6. The ramp door patio deck system of claim 5further comprising a rail having a first rail section, a second railsection, and a third rail section, the first rail section beingconnectable to the door frame and removably connectable to the one sideof the vehicle ramp door, the second rail section being connectable tothe door frame and removably connectable to the opposite side of thevehicle ramp door, and the third rail section being removablyconnectable to a free end of the door between the one side of the doorand the opposite side of the door.
 7. The ramp door patio deck system ofclaim 4 further comprising a post retainer attachable to the vehicleramp door, the post retainer comprising a rotary latch and a coveroverlying the rotary latch.
 8. The ramp door patio deck system of claim7 further comprising a removable rail section, the removable railsection comprising a post, the post having a head and a shaft, the postconfigured for selective engagement with the rotary latch with the headof the post between the door and the rotary latch.
 9. The ramp doorpatio deck system of claim 8 wherein the length of the post isadjustable.
 10. The ramp door patio deck system of claim 4 furthercomprising at least one support leg connectable to the vehicle rampdoor, the at least one support leg being configured to support thevehicle ramp door in the deck position.
 11. A method of installing aramp door patio deck system on a vehicle ramp door, wherein the vehicleramp door is pivotable in a door frame between a closed position and adeck position, the method comprising: (a) securing a first cable mountproximate a first side of the vehicle ramp door and proximate a free endof the vehicle ramp door; (b) securing a second cable mount proximate asecond side of the vehicle ramp door, opposite from the first sidethereof, and intermediate the free end and a pivot end of the vehicleramp door, the pivot end of the vehicle ramp door being further from thefirst cable mount than from the second cable mount; (c) connecting afirst cable between the door frame and the first cable mount; (d)connecting a second cable between the door frame and the second cablemount; and (e) attaching a rail to the vehicle ramp door.
 12. The methodof claim 11 further comprising attaching a stair to the second side ofthe vehicle ramp door between the free end of the vehicle ramp door andthe second cable mount.
 13. The method of claim 11 further comprisingsecuring at least one support leg to the vehicle ramp door, the at leastone support leg being configured to support the vehicle ramp door in thedeck position.
 14. The method of claim 11 wherein the rail includes afirst rail section, a second rail section, and a third rail section, andwherein step (e) is practiced by removably connecting the first railsection to the door frame and to the first side of the vehicle ramp doorbetween the pivot end and the free end, removably connecting the secondrail section to the door frame and to the second side of the vehicleramp door, and removably connecting the third rail section to the freeend between the first and second sides of the vehicle ramp door.
 15. Themethod of claim 14 wherein step (e) is further practiced by pivotablyconnecting at least one of the first rail section and the second railsection to the door frame.
 16. The method of claim 11 further comprisingattaching a post retainer to the vehicle ramp door, the post retainercomprising a rotary latch and a cover overlying the rotary latch.
 17. Aramp door patio deck system in combination with a vehicle ramp door,wherein the vehicle ramp door is pivotable in a door frame between aclosed position and a deck position, the combination comprising: a firstcable connected between the door frame and the vehicle ramp door; asecond cable connected between the door frame and the vehicle ramp door,wherein the second cable is secured to the vehicle ramp door at aposition closer to the door frame than a position where the first cableis connected to the vehicle ramp door; and a rail secured to the vehicleramp door and surrounding at least a portion of a periphery of thevehicle ramp door, the rail including a side section with a gateslidingly engaged with the side section, and displaceable between anopen position and a closed position, wherein the second cable is securedto the vehicle ramp door at a position adjacent a distal end of the gatewhen the gate is in the open position.
 18. The combination of claim 17,further comprising a stair removably connected to the vehicle ramp doorat a position in line with the gate when the gate is in the closedposition.
 19. The combination of claim 18, wherein the stair ispositioned beyond a reach of the second cable.
 20. The combination ofclaim 17, further comprising at least one support leg connected to thevehicle ramp door, the at least one support leg being configured tosupport the vehicle ramp door in the deck position.